Electrical resonator

ABSTRACT

An acoustic resonator comprises a substrate comprising a cavity. The electrical resonator comprises a resonator stack suspended over the cavity. The resonator stack comprises a first electrode; a second electrode; a piezoelectric layer; and a temperature compensating layer comprising borosilicate glass (BSG).

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional application under 37 C.F.R.§1.53(b) of U.S. patent application Ser. No. 12/494,886 to Kevin J.Grannen, et al. The present application claims priority under 35 U.S.C.§121 from U.S. patent application Ser. No. 12/494,886, and thedisclosure of U.S. patent application Ser. No. 12/494,886 isspecifically incorporated herein by reference.

BACKGROUND

In many electronic applications, electrical resonators are required. Forexample, in many wireless communications devices, radio frequency (RF)and microwave frequency resonators are used as filters to improvereception and transmission of signals. Filters typically includeinductors and capacitors, and more recently resonators.

As will be appreciated, it is desirable to reduce the size of componentsof electronic devices. Many known filter technologies present a barrierto overall system miniaturization. With the need to reduce componentsize, a class of resonators based on the piezoelectric effect hasemerged. In piezoelectric-based resonators, acoustic resonant modes aregenerated in the piezoelectric material. These acoustic waves areconverted into electrical waves for use in electrical applications.

One type of piezoelectric resonator is a Film Bulk Acoustic Resonator(FBAR). The FBAR has the advantage of small size and lends itself toIntegrated Circuit (IC) manufacturing tools and techniques. The FBARincludes an acoustic stack comprising, inter alia, a layer ofpiezoelectric material disposed between two electrodes, Acoustic wavesachieve resonance across the acoustic stack, with the resonant frequencyof the waves being determined by the materials in the acoustic stack.

FBARs are similar in principle to bulk acoustic resonators such asquartz, but are scaled down to resonate at GHz frequencies. Because theFBARs have thicknesses on the order of microns and length and widthdimensions of hundreds of microns, FBARs beneficially provide acomparatively compact alternative to known resonators.

Most FBAR devices have a frequency response having a band passcharacteristic characterized by a center frequency. The resonantfrequency depends on the materials of the FBAR ‘stack’ as well as theirrespective thicknesses. The constituent FBARs have a frequency responsecharacteristic characterized by a resonant frequency. In certain knownFBAR devices in which the material of the piezoelectric material isaluminum nitride (AlN) and the material of the electrodes is molybdenum(Mo), the resonant frequency of the FBAR device has a temperaturecoefficient ranging from approximately −20 ppm/° C. to approximately −35ppm/° C. Such temperature coefficients reduce the temperature range overwhich the FBAR device incorporating the FBARs can meet its passbandwidth specification. Such temperature coefficients additionallyreduce manufacturing yield, because the bandwidth limits to which theFBAR devices are tested have to be inset to ensure that the FBAR devicewill meet its bandwidth specification over its entire operatingtemperature range.

Illustratively, the change in the temperature coefficient of theconstituent materials of the FBAR device can result in a change in theresonant frequency of the FBAR device of several MHz over a typicaloperating temperature range of −30° C. to +85° C. As should beappreciated, variation in the resonant frequency (also referred to asthe frequency shift) with temperature may be so great as to shift theoperating frequency of the device outside its desired operatingfrequency range. For example, if the FBAR device is a component of asignal filter, a change in the resonant frequency could impact thepassband of the filter beyond an acceptable limit.

In an effort to reduce the variation of resonant frequency withtemperature of FBAR devices, temperature compensation layers have beendeveloped. In certain known FBAR devices, the temperature-compensatingelement has a temperature coefficient opposite in sign to thetemperature coefficient of the piezoelectric element. While somematerials are useful in temperature compensation layers, there aredrawbacks in their incorporation into fabrication of many FBAR devices.

What are needed, therefore, are an acoustic resonator structure and itsmethod of fabrication that overcome at least the shortcomings of knowndescribed above.

BRIEF DESCRIPTION OF THE DRAWINGS

The illustrative embodiments are best understood from the followingdetailed description when read with the accompanying drawing figures. Itis emphasized that the various features are not necessarily drawn toscale. In fact, the dimensions may be arbitrarily increased or decreasedfor clarity of discussion. Wherever applicable and practical, likereference numerals refer to like elements.

FIG. 1A shows a cross-sectional view of an FBAR in accordance with arepresentative embodiment.

FIG. 1B shows a cross-sectional view of a stacked bulk acousticresonator in accordance with a representative embodiment.

FIGS. 2A-2D show cross-sectional views of a method of fabricating anFBAR in accordance with an illustrative embodiment.

FIG. 3 shows a graph showing the dependence of temperature compensationon BSG thickness.

DEFINED TERMINOLOGY

The terms ‘a’ or ‘an’, as used herein are defined as one or more thanone.

The term ‘plurality’ as used herein is defined as two or more than two.

In addition to their ordinary meanings, the terms ‘substantial’ or‘substantially’ mean to with acceptable limits or degree to one havingordinary skill in the art. For example, ‘substantially cancelled’ meansthat one skilled in the art would consider the cancellation to beacceptable.

In addition to their ordinary meanings, the terms ‘approximately’ meanto within an acceptable limit or amount to one having ordinary skill inthe art. For example, ‘approximately the same’ means that one ofordinary skill in the art would consider the items being compared to bethe same.

DETAILED DESCRIPTION

In the following detailed description, for purposes of explanation andnot limitation, specific details are set forth in order to provide athorough understanding of illustrative embodiments according to thepresent teachings. However, it will be apparent to one having ordinaryskill in the art having had the benefit of the present disclosure thatother embodiments according to the present teachings that depart fromthe specific details disclosed herein remain within the scope of theappended claims. Moreover, descriptions of well-known apparati andmethods may be omitted so as to not obscure the description of theillustrative embodiments. Such methods and apparati are clearly withinthe scope of the present teachings.

FIG. 1A is a cross-sectional view of an electrical resonator structure100 in accordance with an illustrative embodiment. The electricalresonator structure 100 comprises a substrate 101, a first electrode 102disposed over the substrate 101, a layer of piezoelectric layer 103, atemperature compensation layer 104 and a second electrode 105. Theelectrical resonator structure 100 also comprises a cavity 106 formed inthe substrate 101. With the placement of the first and second electrodes102, 105, the piezoelectric layer 103 and the temperature compensationlayer 104 (collectively referred to as the resonator stack) over thecavity the electrical resonator structure 100 comprises an FBARstructure.

Notably, more than one resonator stack is contemplated. For example,another resonator stack comprising the first and second electrodes 102,105, the piezoelectric layer 103 and the temperature compensation layer104 may be provided over the resonator stack as shown in shown in FIG.1B. This structure provides a stack bulk acoustic resonator (SBAR). TheSBAR is fabricated by repeating the fabrication sequence of theresonator stack after forming the resonator stack shown in FIG. 1A, andbefore removing sacrificial material as discussed below. In arepresentative embodiment, the SBAR comprises first electrode 102disposed over the substrate 101, a layer of piezoelectric layer 103, atemperature compensation layer 104, second electrode 105. Anothertemperature compensation layer 107 is provided over the second electrode105. An electrode 108 is provided over the temperature compensationlayer 107, and in tandem a second piezoelectric layer 109 and anotherelectrode 110 are provided over the temperature compensation layer.

The placement of the temperature compensation layers 104, 107 betweenthe piezoelectric layer 103 and the second electrode 105 as shown inFIG. 1A is merely illustrative. Furthermore, the placement of the othertemperature compensation layer 107 beneath the electrode 108 is alsomerely illustrative. Notably, the temperature compensation layers104,107 may be provided between other layers in the resonator stack. Forexample, the temperature compensation layer 104 may be provided betweenthe first electrode 102 and the piezoelectric layer 103. Similarly, theother temperature compensation layer 107 may be provided between theelectrode 108 and the second piezoelectric layer 109. In accordance witha representative embodiment, the temperature compensation layers 104,107 each comprise borosilicate glass (BSG) comprising boron in the rangeof approximately 0.1% to approximately 5.0% where the concentration ofboron is either a mass or weight percent or an atomic percent. Asdescribed more fully below, BSG comprises a temperature coefficient thatis opposite in sign to the temperature coefficient of the piezoelectricmaterial comprising the piezoelectric layer 103, and the secondpiezoelectric layer 109, in the embodiment comprising an SBAR. Moregenerally, BSG is selected to provide a temperature coefficient that isopposite of the composite temperature coefficient of the other layers ofthe resonator stack of the FBAR, and of the SBAR.

The doping level of boron in the BSG is selected to provide a suitabledegree of temperature compensation while not interfering with thermalconstraints in processing the electrical resonator structure 100. Asdescribed above, the doping level of boron in the BSG layer comprisingthe temperature compensation layer 104 is in the range of 0.1% toapproximately 5.0% (weight percent or atomic percent). The greater thedoping level of boron in the temperature compensation layer 104, thegreater the temperature coefficient. However, as the doping levelincreases, the melting point of BSG decreases. In order to ensure thatcertain higher temperature processes (e.g., deposition of thepiezoelectric layer 103) do not cause flow of the temperaturecompensation layer 104 comprising the BSG, the doping level ismaintained in the range set forth above. As an example, the aluminumnitride is deposited at temperatures that may approach 500° C., atemperature that may cause reflow concerns when using BSG with a highconcentration of boron. To prevent this reflow from happening, theconcentration of boron is kept low enough to prevent reflow but highenough to enable adequate temperature compensation of the FBAR/SBARstructure.

FIG. 2A shows a cross-sectional view of the substrate 101 comprising thecavity 106 formed in the substrate, and substantially filled with asacrificial material 201. Illustratively, the substrate 101 is silicon(e.g., monocrystalline silicon) and the sacrificial material 201comprises silicon dioxide doped with phosphorous, and often referred toas phosphosilicate glass (PSG). The formation of the cavity 106 and thefilling thereof with sacrificial material 201 are known. For example,the formation of the cavity 106 and the disposition of the sacrificialmaterial 201 therein may be effected as discussed in U.S. Pat. No.6,384,697 to Ruby, et al., entitled “Cavity Spanning Bottom Electrode ofa Substrate-Mounted Bulk Wave Acoustic Resonator.” This patent isassigned to the assignee of the present application, and is specificallyincorporated herein by reference. After formation of the sacrificialmaterial 201, a chemical mechanical polish step is effected so that asurface 202 of the sacrificial material is substantially flush with asurface 203 of the substrate 101.

FIG. 2B shows a cross-sectional view of the substrate 101 comprising thesacrificial material 201 after forming of the first electrode 102 andthe piezoelectric layer 103. Notably, the first electrode 102 spanscavity 106 and is disposed over surface 202 of the sacrificial material201 and the surface 203 of the substrate 101.

FIG. 2C shows a cross-sectional view of the substrate 101 comprising thesacrificial material 201 after forming of the first electrode 102, thepiezoelectric layer 103 and the temperature compensation layer 104. Asdescribed above, the temperature compensation layer 104 comprises BSG.The thickness of the layer is selected based on the desired resonancefrequency of the resonator structure 100. For example, if the desiredresonance frequency if the electrical resonator structure 100 isapproximately 1900 MHz, then the temperature compensation layer isdeposited at a thickness in the range of approximately 500 Å to 2000 Å.Generally, the thickness of the temperature compensation layer 104 is inthe range of approximately 200 Å to approximately 10000 Å.

In accordance with a representative embodiment, the BSG layer of isfabricated using a known and comparatively low temperature plasmaenhanced chemical vapor deposition (PECVD) process. Illustratively, thePECVD process is carried out at a temperature in the range ofapproximately 300° C. to approximately 400° C. Illustratively, the BSGlayer by PECVD can include use of helium (0 sccm to 5000 sccm), nitrousoxide (0 sccm to 100 sccm), silane or tetraethylorthosilicate (TEOS) (0sccm to 50 sccm), and diborane (0 sccm to 50 sccm) at an operatingpressure of approximately 0 Torr to approximately 10 Torr at a power ofapproximately 0 W to approximately 500 W. The temperature of the processis illustratively at approximately 0° C. to approximately 500° C.Alternatively, the temperature compensation layer 104 comprising BSG maybe formed using a radio frequency (RF) sputtering of a borosilicateglass target known to one of ordinary skill in the art. Furthermore, amodulation of the boron and nitrogen concentration in the glass (SiC) inthe temperature compensation layer 104 may be effected to provide notonly suitable temperature compensation of the resonator stack, but alsoresistance to used in the removal of the sacrificial material 201 inlater processing. As should be appreciated by one of ordinary skill inthe art, in forming the temperature compensation layers 104, 107comprising BSG, boron may be incorporated in an atomic form or in a formbonded to the silicon and/or oxygen atoms.

FIG. 2D shows a cross-sectional view of the substrate 101—comprising thesacrificial material 201 after forming of the first electrode 102, thepiezoelectric layer 103, the temperature compensation layer 104 and thesecond electrode. The formation of the first electrode 102 and thepiezoelectric layer 103 and the second electrode 105 may be asdescribed, for example, in one or more of the following commonly ownedU.S. Pat. Nos. 5,587,620; 5,873,153; 6,384,697; 6,507,983; and 7,275,292to Ruby, et al.; U.S. Pat. No. 6,828,713 to Bradley, et, al; andcommonly owned U.S. Patent Application Publications: 20070205850 toJamneala, et. al.; 20080258842 to Ruby, et al.; and 20060103492 to Feng,et al. The disclosures of these patents and patent applicationpublications are specifically incorporated herein by reference. Notably,the teachings of these patents and patent publications is intended to beillustrative of methods, materials and structures useful to the presentteachings, but in no way limiting to the present teachings.

Finally, after forming of the second electrode 105, the sacrificialmaterial 201 is removed using a suitable etchant through a known releaseprocess. For example, if the sacrificial layer material 201 is PSG, anHF solution may be used. After release of the sacrificial material 201,the resonator structure comprising the temperature compensation layer104, the piezoelectric layer 103 and first and second electrodes 102,105over the cavity 106 as shown in FIG. 1 is realized. It is emphasizedthat the fabrication sequence and the materials and methods are merelyillustrative and that other fabrication sequences, materials and methodsare contemplated. For example, as described above, the placement of thetemperature compensation layer may be other than shown and described,and generally may be placed between any two layers of the resonatorstack between the first electrode 102 and the second electrode 105.

FIG. 3 shows a graph showing the dependence of temperature compensationon BSG thickness. Notably, the temperature coefficient for the BSG isless than one for the parameters and thicknesses shown.

In accordance with illustrative embodiments, electrical resonatorscomprising a temperature compensation layer in a resonator stacksuspended over a cavity are described. One of ordinary skill in the artappreciates that many variations that are in accordance with the presentteachings are possible and remain within the scope of the appendedclaims. These and other variations would become clear to one of ordinaryskill in the art after inspection of the specification, drawings andclaims herein. The invention therefore is not to be restricted exceptwithin the spirit and scope of the appended claims.

We claim:
 1. An acoustic resonator, comprising: a substrate; a cavity inthe substrate; and a resonator stack suspended over the cavity andcomprising: a first electrode; a second electrode; a piezoelectriclayer; and a temperature compensating layer comprising borosilicateglass (BSG).
 2. An acoustic resonator as claimed in claim 1, wherein thetemperature compensation layer is disposed between the first electrodeand the piezoelectric layer.
 3. An acoustic resonator as claimed inclaim 1, wherein the temperature compensation layer is disposed betweenthe second electrode and the piezoelectric layer.
 4. An acousticresonator as claimed in claim 1, wherein the temperature compensationlayer is disposed over the substrate and beneath the first electrode. 5.An acoustic resonator as claimed in claim 1, wherein the temperaturecompensation layer is disposed over the second electrode.
 6. An acousticresonator as claimed in claim 1, further comprising a second resonatorstack disposed over the first resonator stack, the second resonatorstack comprising: a third electrode; a fourth electrode; a secondpiezoelectric layer; and a second temperature compensating layercomprising borosilicate glass (BSG).
 7. An acoustic resonator as claimedin claim 1, wherein the temperature compensation layer is disposedbetween the first electrode and the piezoelectric layer.
 8. An acousticresonator as claimed in claim 1, wherein the second temperaturecompensation layer is disposed between the fourth electrode and thesecond piezoelectric layer.
 9. An acoustic resonator as claimed in claim1, wherein the second temperature compensation layer is disposed overthe second electrode and beneath the third electrode.
 10. An acousticresonator as claimed in claim 1, wherein the second temperaturecompensation layer is disposed over the fourth electrode.
 11. Anacoustic resonator as claimed in claim 1, wherein a concentration ofboron in the temperature compensation layer is in a range ofapproximately 0.1% to approximately 5.0% by weight percent, or by atomicpercent.
 12. An acoustic resonator as claimed in claim 6, wherein aconcentration of boron in the first temperature compensation layer, andin the second temperature compensation layer is in a range ofapproximately 0.1% to approximately 5.0% by weight percent, or by atomicpercent.
 13. An acoustic resonator as claimed in claim 1, wherein thetemperature compensation layer has a thickness in the range ofapproximately 500 Å to approximately 2000 Å.
 14. An acoustic resonatoras claimed in claim 1, wherein the temperature compensation layer has athickness in the range of approximately 200 Å to approximately 10000 Å.15. An acoustic resonator as claimed in claim 6, wherein the firsttemperature compensation layer and the second temperature compensationlayer each have a thickness in the range of approximately 500 Å toapproximately 2000 Å.
 16. An acoustic resonator as claimed in claim 6,wherein the first temperature compensation layer and the secondtemperature compensation layer each have a thickness in the range ofapproximately 200 Å to approximately 10000 Å.
 17. An acoustic resonatoras claimed in claim 1, wherein a concentration of boron in the BSG inthe temperature compensation layer is low enough to prevent reflow ofthe piezoelectric layer, but high enough to enable adequate temperaturecompensation of the acoustic resonator.
 18. An acoustic resonator asclaimed in claim 6, wherein a concentration of boron in the BSG in eachof the first and second temperature compensation layers is low enough toprevent reflow of the piezoelectric layer, but high enough to enableadequate temperature compensation of the acoustic resonator.